Self-adhered roof system and components

ABSTRACT

A self-adhered roof system includes a plurality of waterproof self-adhering base sheets that are self-adhered by watertight bonds to underlying and overlying layers of the roof system and, preferably, waterproof fire-retardant cap sheets that are adhered to an underlying layer formed of the self-adhering base sheets. Base sheet assemblies that each include a base sheet with release sheets overlying its bottom and top major surfaces and, preferably, fire-retardant cap sheet assemblies that each include a fire-retardant cap sheet with release sheets overlying its bottom major surface and a selvage edge portion of its top major surface are utilized to form the self-adhered roof system. The self-adhering base sheets may be used with cap sheets other than fire-retardant cap sheets and with other roof components.

BACKGROUND OF THE INVENTION

The subject invention relates to roof system components and a roofsystem that utilizes those components. More specifically, the subjectinvention relates to waterproof self-adhering base sheet roof systemcomponents and a roof system that includes at least one inner layer ofthe waterproof self-adhering base sheets self-adhered by watertightbonds to underlying and overlying layers of the roof system. Preferably,the roof system components also include waterproof fire-retardant capsheets and the roof system includes a layer of those cap sheets that areadhered to an underlying layer of the self-adhering base sheets by theself-adhering base sheets.

Current self-adhered modified bitumen roof systems typically include anuppermost layer of cap sheets and one or more underlying roof systemlayers. The underlying roof system layer or layers may be: one or morebase sheet layers and a roof deck; one or more base sheet layers, one ormore insulation layers, and a roof deck; one or more insulation layersand a roof deck; or a roof deck.

These current self-adhered roof systems include granule surfaced andsmooth surfaced cap sheets that form the topmost layer of the roofsystems. One type of current cap sheet includes a reinforcementsubstrate, such as a fiberglass mat, polyester fiber mat, or afiberglass/polyester fiber mat, which is encapsulated within top andbottom layers of modified bitumen. The modified bitumen is modified tomake the bitumen a self-adhering material. Another type of current capsheet includes a reinforcement substrate, such as a fiberglass mat,polyester fiber mat, or a fiberglass/polyester fiber mat, which isencapsulated within top and bottom layers of conventionally modifiedbitumen that is not a self-adhering material. The bottom major surfacesof such cap sheets are coated with self-adhering materials. Theself-adhering modified bitumen or the coatings of other self-adheringmaterials on the bottom major surfaces of these cap sheets are used toself-adhere the cap sheets to underlying roof system layers.

Where the current self-adhered roof systems include one or more innerbase sheet layers, the base sheets forming those inner layers includereinforcement substrates, such as a fiberglass mat, polyester fiber mat,or a fiberglass/polyester fiber mat, which are encapsulated within topand bottom layers of modified bitumen that is modified to make thebitumen a self-adhering material. The bottom major surfaces of thesebase sheets are self-adhering surfaces that are used to bond the basesheets to underlying roof system layers. However, the top major surfacesof these base sheets are surfaced with non-adhering materials, such asbut not limited to talc, sand, or polymeric film, which remain on thebase sheets after installation so that the top major surfaces of thesebase sheets are not self-adhering surfaces.

The modification of bitumen to make the bitumen a self-adhering bitumenrather than a conventionally modified bitumen requires: the addition ofpolymers to the bitumen that are other than the polymers normally usedto make a conventional modified bitumen; the addition of conventionalpolymers to the bitumen in concentrations very different from thosenormally used to make a conventional modified bitumen; and/or theaddition of other vehicles and modifiers to render the bitumen softerand more tacky at application and service temperatures ranging fromabout 40° F. to about 120° F. Thus, when compared to the conventionalStyrene-Butadiene-Styrene (SBS) or Amorphous Polypropylene (APP)modified bitumen of conventional cap and base sheets, the modifiedself-adhering bitumen used in these cap and base sheets are softer andless resistant to flow (less viscous) when heated or subjected tocompressive forces.

When tested in accordance with ASTM Test Designation E 108-00, approvedJan. 10, 2000, published April 2000, and entitled Standard Test Methodsfor Fire Tests of Roof Coverings (hereinafter “ASTM Test E 108”), roofsystems made with conventional cap and base sheets typically meet therequirements of Factory Mutual for a Class A rated roof system. Whentested in accordance with Underwriters Labortories, Inc. testdesignation UL 790 (hereinafter “UL Test 790”), roof systems made withconventional cap and base sheets typically meet the requirements ofUnderwriters Laboratories, Inc. for a Class A rated roof system.However, when tested in accordance with ASTM Test E 108 by FactoryMutual or in accordance with UL Test 790 by Underwriters Laboratories,Inc., roof systems made with cap and base sheets utilizing the softer,less viscous, self-adhering bitumen are less fire resistant than theroof systems made with conventional cap and base sheets and typically donot achieve a Class A rating.

In addition to being less fire resistant than roof systems made withconventional cap and base sheets, current self-adhered roof systemspresent another problem. The surfacing of the top major surfaces of thebase sheets (inner ply sheets) with talc, sand, polymeric films, orother non-adhesive surfacing materials that remain on the base sheetsafter installation inhibits the adhesive bonding of self-adhering orconventional cap sheets and other roof system components to the topmajor surfaces of these base sheets.

SUMMARY OF THE INVENTION

The subject invention provides a unique and effective solution to thecurrent problems associated with roof systems utilizing cap and basesheets made of self-adhering bitumen or other self-adhering materials.The subject invention retains the convenience and labor savings of aself-adhered roof system, enhances the adhesive bonding betweenself-adhered roof system layers; and provides a self-adhered roof systemthat when tested in accordance with ASTM Test E 108 meets Factory Mutualrequirements for a Class A rated roof system and when tested inaccordance with UL Test 790 meets the requirements of UnderwritersLaboratories, Inc. for a Class A rated roof system.

The self-adhered roof system of the subject invention includes aplurality of waterproof self-adhering base sheets that are self-adheredby watertight bonds to underlying and overlying layers of the roofsystem and, preferably, waterproof fire-retardant cap sheets that areadhered to an underlying layer formed of the self-adhering base sheetsby the self-adhering base sheets. Base sheet assemblies of the subjectinvention and, preferably, fire-retardant cap sheet assemblies of thesubject invention are utilized to form a self-adhered roof system thatpasses ASTM Test E 108 and UL Test 790 with a Class A rating.

The base sheet assembly of the subject invention has: a waterproofself-adhering base sheet for forming a watertight roof system layer thatwill self-adhere to an overlying roof system layer and an underlyingroof system layer, a bottom surface release sheet forming a bottomsurface of the base sheet assembly, and a top surface release sheetforming a top surface of the base sheet assembly. The waterproofself-adhering base sheet of the assembly has a reinforcing layerencapsulated within self-adhering bitumen that forms the bottom majorsurface and the top major surface of the waterproof self-adhering basesheet. The bottom surface release sheet overlies and is coextensive withor substantially coextensive with the bottom major surface of thewaterproof self-adhering base sheet to protect the bottom major surfaceof the waterproof self-adhering base sheet from degradation, e.g throughthe accumuation of dust on the surface, during storage, shipment andhandling. The bottom surface release sheet is removable from the bottommajor surface of the waterproof self-adhering base sheet immediatelyprior to installation of the waterproof self-adhering base sheet on anunderlying layer of a roof system. With the bottom surface release sheetremoved from the bottom major surface of the waterproof self-adheringbase sheet, the bottom major surface of the waterproof self-adheringbase sheet can be self-adhered by a watertight bond to an underlyingroof system layer primarily by the application of pressure. Thetop-surface release sheet overlies and is substantially coextensive withthe top major surface of the waterproof self-adhering base sheet toprotect the top major surface of the waterproof self-adhering base sheetfrom degradation during storage, shipment and handling. The top surfacerelease sheet is removable from the top major surface of the waterproofself-adhering base sheet immediately prior to an application of anoverlying roof layer to the top major surface of the waterproofself-adhering base sheet. With the top surface release sheet removedfrom the top major surface of the waterproof self-adhering base sheet,the top major surface the waterproof self-adhering base sheet can beself-adhered by a watertight bond to an overlying roof system layerprimarily by the application of pressure.

The cap sheet assembly of the subject invention has: a waterprooffire-retardant cap sheet for forming a watertight topmost layer of aroof system that is adhered to an underlying roof system layer formed bya plurality of the waterproof self-adhering base sheets of the subjectinvention, a bottom surface release sheet forming a bottom surface ofthe cap sheet assembly, and a top surface selvage edge portion releasesheet forming one lateral edge portion of a top surface of the cap sheetassembly. The waterproof fire-retardant cap sheet has a reinforcinglayer encapsulated within a fire-retardant modified bitumen, which formsthe bottom major surface and a selvage edge portion of the top majorsurface of the waterproof fire-retardant cap sheet, and a top majorsurface surfacing layer forming a remainder of the top major surface ofthe waterproof fire-retardant cap sheet. The bottom surface releasesheet overlies and is coextensive with or substantially coextensive withthe bottom major surface of the waterproof fire-retardant cap sheet toprotect the bottom major surface of the waterproof fire-retardant capsheet from degradation during storage, shipment and handling. The bottomsurface release sheet is removable from the bottom major surface of thewaterproof fire-retardant cap sheet immediately prior to installation ofthe waterproof fire-retardant cap sheet on an underlying roof systemlayer formed by a plurality of the waterproof self-adhering base sheetsto form a watertight bond with the underlying roof system layerprimarily by the application of pressure. The top selvage edge portionrelease sheet overlies and is coextensive with or substantiallycoextensive with the selvage edge portion of the top major surface ofthe waterproof fire-retardant cap sheet to protect the selvage edgeportion of the top major surface of the waterproof fire-retardant capsheet from degradation during storage, shipment and handling. The topselvage edge portion release sheet is removable from the selvage edgeportion of the top major surface of the waterproof fire-retardant capsheet immediately prior to an application and bonding of an overlappingportion of an adjacent cap sheet to the selvage edge portion of the topmajor surface of the waterproof fire-retardant cap sheet to form awatertight bond with the overlapping portion of the adjacent cap sheet.

The self-adhering base sheets of the subject invention may be used withcap sheets other than the fire-retardant cap sheets of the subjectinvention and with other roof components.

In this specification and claims, a “self-adhering surface” or a“self-adhering major surface” of a roof component, such as a base sheetor a cap sheet, is a surface that, primarily with the application ofpressure, forms a watertight bond with the surface of another roofcomponent without the need to use heat, flame, an additional adhesivematerial, or hot asphalt material. In this specification and claims, a“self-adhering” roof component, such as a self-adhering base sheet or aself-adhering cap sheet, is a roof component that includes at least oneself adhering surface and/or self-adhering major surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial schematic view, from above, of a self-adhered roofsystem of the subject invention with portions broken away to better showthe roof system components.

FIG. 2 is a partial schematic perspective view of a base sheet assemblyof the subject invention.

FIG. 3 is a transverse cross section through the base sheet assembly ofFIG. 2 taken substantially along lines 3-3 of FIG. 2.

FIG. 4 is a partial schematic perspective view of a cap sheet assemblyof the subject invention.

FIG. 5 is a transverse cross section through the cap sheet assembly ofFIG. 4 taken substantially along lines 5-5 of FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 1, the self-adhered roof system 20 of the subjectinvention includes waterproof self-adhering base sheets 22 and capsheets 24 that, preferably, are the waterproof fire-retardant cap sheetsof the subject invention. The waterproof self-adhering base sheets 22 ofthe roof system are self-adhered by watertight bonds both to each otherto form inner roof system layers and to underlying and overlying layersof the roof system. When used in the roof system 20, the waterprooffire-retardant cap sheets 24 are not self-adhering, but are adhered toeach other, e.g. by a cold applied adhesive, and are adhered to anunderlying layer formed of the self-adhering base sheets 22 by theself-adhering base sheets.

In a preferred embodiment of the invention, the exposed top or outerlayer of the self-adhered roof system 20 is formed by the waterprooffire-retardant cap sheets 24 and the inner roof system layers of theself-adhered roof system 20 are formed by: one or more layers of thewaterproof self-adhering base sheets 22 and a roof deck 26; or one ormore layers of the waterproof self-adhering base sheets 22, one or moreinsulation layers 28, and a roof deck 26. In addition to the one or moreinner roof system layers formed by the waterproof self-adhering basesheets 22, for certain applications, the lowermost layer of theself-adhered roof system 20, formed by the self-adhering base sheets 22,may be self-adhered to an inner layer formed of conventional base sheetsthat are in turn bonded by a conventional cold applied adhesive to aroof deck 26 or an insulation layer 28.

Each self-adhering inner layer of the self-adhered roof system 20 isformed by a plurality of overlapping base sheets 22 that areself-adhered to the other base sheets of the self-adhering inner layerto form the self-adhering inner layer. In addition, the self-adheringbase sheets 22 of the self-adhering inner layer thus formed are selfadhered to overlying and underlying layers of the self-adhered roofsystem. As shown in FIG. 1, a self-adhering layer 30 of self-adheringbase sheets 22 is self-adhered to an overlying outer layer 32 of thefire-retardant cap sheets 24 and an underlying inner layer 34 ofself-adhering base sheets 22 or conventional base sheets. Where theunderlying layer 34 is also formed of self-adhering base sheets 22, theunderlying layer may be self-adhered to the insulation layer 28, asshown in FIG. 1, to another base sheet layer, or directly to the roofdeck 26. The roof deck 26 may be a wood, metal or concrete roof deck.

As shown in FIGS. 2 and 3, the base sheet assembly 40 of the subjectinvention has: a waterproof self-adhering base sheet 22, a bottomsurface release sheet 42 that forms a bottom surface of the base sheetassembly, and a top surface release sheet 44 that forms a top surface ofthe base sheet assembly. With the release sheets 42 and 44 of the basesheet assembly removed, the waterproof base sheet 22 can be self-adheredto other waterproof self-adhering base sheets 22 to form a watertightroof system layer and to an overlying roof system layer and anunderlying roof system layer.

The waterproof self-adhering base sheet 22 of the base sheet assembly 40may be of various lengths, widths, and thicknesses, but preferably is 10to 20 meters long, 880 to 1020 millimeters wide, and 1 to 4 millimetersthick. The waterproof self-adhering base sheet has a reinforcing layer46 encapsulated within self-adhering bitumen. The self-adhering bitumenof the waterproof self-adhering base sheet 22 forms a bottom layer 48and a bottom major surface 50 of the waterproof self-adhering base sheetand a top layer 52 and a top major surface 54 of the waterproofself-adhering base sheet. The bottom major surface 50 and the top majorsurface 54 of the waterproof self-adhering base sheet 22 areself-adhering surfaces free of surfacing materials such as talc, sand,polymeric films, or other non-adhesive materials.

The reinforcing layer 46 of the waterproof self-adhering base sheet 22is typically a non-woven polyester, fiberglass, or polyester/fiberglassreinforcement mat. The modified bitumen is bitumen modified to be aself-adhering material. An example of modified bitumen that can be usedin the waterproof self-adhering base sheet 22 has the followingcomposition: 40% to 75% by weight asphalt having a penetration whentested @ 25° C. per ASTM D5 of 40 to 200 Dmm and a Ring & Ball SofteningPoint of 200 to 80° C. when tested per ASTM D36; 0% to 14% by weightStyrene-Butadiene-Styrene (SBS) radical polymer; 0% to 14% by weightStyrene-Butadiene (SB) Diblock polymer; 0% to 20% by weight Colemanite;0% to 20% by weight Dolomite containing approximately 20% to 30%magnesium carbonate; 0% to 20% by weight Calcium Carbonate; 0.5% to 15%by weight hydrocarbon resin; 0% to 15% by weight Severely HydrotreatedNapthenic Process; and 0% to 0.5% by weight anti-oxidant. The asphaltused in the modified self-adhering bitumen may be, but is not limitedto, asphalt marketed by Phillips Conoco Wood River under the tradedesignation PG58-22. The Styrene-Butadiene-Styrene (SBS) radical polymerused in the modified self-adhering bitumen may be, but is not limitedto, Styrene-Butadiene-Styrene (SBS) radical polymer marketed byPolimieri Europa under the trade designation 161B. The Styrene-Butadiene(SB) Diblock polymer used in the modified self-adhering bitumen may be,but is not limited to, Styrene-Butadiene (SB) Diblock polymer marketedby Polimieri Europa under the trade designation 6320. The Dolomite usedin the modified self-adhering bitumen may be, but is not limited to,Dolomite marketed by Global Filler Products under the trade designationGFP 250. The Calcium Carbonate used in the modified self-adheringbitumen may be, but is not limited to, Calcium Carbonate marketed byHuber under the trade designation Q 200. The hydrocarbon resin used inthe modified self-adhering bitumen may be, but is not limited to,hydrocarbon resin marketed by Sunbelt under the trade designationSB2296. The Severely Hydrotreated Napthenic Process used in the modifiedself-adhering bitumen may be, but is not limited to, SeverelyHydrotreated Napthenic Process marketed by Ergon Refining under thetrade designation Hygard L 750.

The bottom surface release sheet 42 of the base sheet assembly 40 may bea conventional release sheet, such as but not limited to, a polymeric orpaper sheet having one or both major surfaces treated with silicone oranother a suitable release agent. The bottom surface release sheet 42overlies and is coextensive with or substantially coextensive with thebottom major surface 50 of the waterproof self-adhering base sheet 22 toprotect the self-adhering bottom major surface 50 of the waterproofself-adhering base sheet from damage, such as but not limited to theaccumulation of dust or other non-adhesive materials on the surfaceduring storage, shipment and handling. The bottom surface release sheet42 is removable from the bottom major surface 50 of the waterproofself-adhering base sheet 22 immediately prior to installation of thewaterproof self-adhering base sheet on an underlying layer of a roofsystem. With the bottom surface release sheet 42 removed from the bottommajor surface 50 of the waterproof self-adhering base sheet 22, thebottom major surface of the waterproof self-adhering base sheet may beself-adhered by a watertight bond to an underlying roof system layerprimarily by the application of pressure.

The top surface release sheet 44 of the base sheet assembly 40 may be aconventional release sheet, such as but not limited to, a polymeric orpaper sheet having one or both major surfaces treated with silicone oranother a suitable release agent. The top surface release sheet 44overlies and is substantially coextensive with the top major surface 54of the waterproof self-adhering base sheet 22 to protect theself-adhering top major surface of the waterproof self-adhering basesheet from damage, such as but not limited to the accumulation of dustor other non-adhesive materials on the surface during storage, shipmentand handling. The top surface release sheet 44 is removable from the topmajor surface 54 of the waterproof self-adhering base sheet 22immediately prior to an application of an overlying roof layer to thetop major surface of the waterproof self-adhering base sheet. With thetop surface release sheet 44 removed from the top major surface 54 ofthe waterproof self-adhering base sheet 22, the top major surface 54 thewaterproof self-adhering base sheet may be self-adhered by a watertightbond to an overlying roof system layer primarily by the application ofpressure.

As shown in FIGS. 4 and 5, the cap sheet assembly 60 of the subjectinvention has: a waterproof fire-retardant cap sheet 24, a bottomsurface release sheet 62 that forms a bottom surface of the cap sheetassembly, and a top surface selvage edge portion release sheet 64 thatforms one lateral edge portion of a top surface of the cap sheetassembly. With the bottom release sheet 62 of the cap sheet assemblyremoved, the waterproof fire-retardant cap sheet 24 can be adhered to anunderlying roof system layer formed by a plurality of the waterproofself-adhering base sheets 22 by pressing the cap sheet 24 against theself-adhering surface of the underlying roof system layer formed by thewaterproof self-adhering base sheets 22. With the top surface selvageedge portion release sheet 64 removed, the selvage edge portion of thecap sheet 24 may be bonded to an overlapping lateral edge portion ofanother cap sheet to form a watertight topmost layer of a roof system,e.g. primarily by the application of pressure and heat, a cold appliedadhesive, sealing tape, etc.

The waterproof fire-retardant cap sheet 24 of the cap sheet assembly 60may be of various lengths, widths, and thicknesses, but preferably, is10 to 15 meters long, 880 to 1020 millimeters wide, and 2 to 5millimeters thick. The waterproof fire-retardant cap sheet 24 has areinforcing layer 66 encapsulated within fire-retardant modifiedbitumen. The fire-retardant modified bitumen forms a bottom layer 68 anda bottom major surface 70 of the waterproof fire-retardant cap sheet 24.The fire-retardant modified bitumen also forms a top layer 72 and aselvage edge portion surface 74 of the top major surface of thewaterproof fire-retardant cap sheet. The selvage edge portion surface 74of the top major surface of the waterproof fire-retardant cap sheet 24is typically about 75 to 520 millimeters wide and extends along onelateral edge of the cap sheet for the entire length of the cap sheet.The remainder 76 of the top major surface of the waterprooffire-retardant cap sheet 24 is surfaced with a conventional surfacingmaterial such as but not limited to roofing granules, sand, or othercoating materials. The bottom major surface 70 and the selvage edgeportion 74 of the top major surface of the waterproof fire-retardant capsheet 24, while not self-adhering surfaces, are free of surfacingmaterials such as talc, sand, polymeric films or other non-adhesivematerials to facilitate the bonding of the bottom major surface 70 ofthe cap sheet to an underlying roof system layer of self-adhering basesheets 22 and the selvage edge portion surface 74 of the cap sheet to anoverlapping lateral edge portion of another cap sheet.

The reinforcing layer 66 of the waterproof fire-retardant cap sheet 24is typically a non-woven polyester, fiberglass, or polyester/fiberglassreinforcement mat. The modified bitumen is bitumen, modified withfire-retardant materials, polymers, fillers and additives, to be afire-retardant material. An example of modified bitumen that can be usedin the waterproof fire-retardant cap sheet 24 has the followingcomposition: 40% to 75% by weight asphalt having a penetration whentested @ 25° C. per ASTM D5 of 40 to 200 Dmm and a Ring & Ball SofteningPoint of 200 to 80° C. when tested per ASTM D36; 4% to 12% by weightStyrene-Butadiene-Styrene (SBS) radical polymer; 10% to 35% by weightColemanite; 10% to 30% by weight Dolomite containing approximately 20%to 30% magnesium carbonate; 0% to 10% by weight Calcium Carbonate; and0% to 0.5% by weight anti-oxidant. The asphalt used in the modifiedfire-retardant bitumen may be, but is not limited to, asphalt marketedby Phillips Conoco Wood River under the trade designation PG58-22. TheStyrene-Butadiene-Styrene (SBS) radical polymer used in the modifiedfire-retardant bitumen may be, but is not limited to,Styrene-Butadiene-Styrene (SBS) radical polymer marketed by PolimieriEuropa under the trade designation 161B. The Dolomite used in themodified self-adhering bitumen may be, but is not limited to, Dolomitemarketed by Global Filler Products under the trade designation GFP 250.The Calcium Carbonate used in the modified self-adhering bitumen may be,but is not limited to, Calcium Carbonate marketed by Huber under thetrade designation Q 200.

The bottom surface release sheet 62 of the cap sheet assembly 60 may bea conventional release sheet, such as but not limited to, a polymeric orpaper sheet having one or both major surfaces treated with silicone oranother a suitable release agent. The bottom surface release sheet 62overlies and is coextensive with or substantially coextensive with thebottom major surface 70 of the waterproof fire-retardant cap sheet 24 toprotect the bottom major surface of the waterproof fire-retardant capsheet from damage, such as but not limited to, the accumulation of dustor other non-adhesive materials on the surface during storage, shipmentand handling that would inhibit the bonding of the surface to an innerlayer of self-adhering base sheets 22. The bottom surface release sheet62 is removable from the bottom major surface 70 of the waterprooffire-retardant cap sheet immediately prior to installation of thewaterproof fire-retardant cap sheet on an underlying self-adhering roofsystem layer formed by a plurality of the waterproof self-adhering basesheets 22 to form a watertight bond with the underlying roof systemlayer primarily by the application of pressure.

The top selvage edge portion release sheet 64 may be a conventionalrelease sheet, such as but not limited to, a polymeric or paper sheethaving one or both major surfaces treated with silicone or another asuitable release agent. The top surface selvage edge portion releasesheet 64 overlies and is coextensive with or substantially coextensivewith the selvage edge portion surface 74 of the top major surface of thewaterproof fire-retardant cap sheet 24 to protect the selvage edgeportion of the top major surface of the waterproof fire-retardant capsheet from damage, such as but not limited to, the accumulation of dustor other non-adhesive materials on the surface during storage, shipmentand handling. The top selvage edge portion release sheet 64 is removablefrom the selvage edge portion 74 of the top major surface of thewaterproof fire-retardant cap sheet 24 immediately prior to anapplication and bonding of an overlapping lateral edge portion of anadjacent cap sheet to the selvage edge portion 74 of the top majorsurface of the waterproof fire-retardant cap sheet to form a watertightbond with the overlapping portion of the adjacent cap sheet.

The self-adhering base sheets 22 of the subject invention may be usedwith cap sheets other than fire-retardant cap sheets 24 of the subjectinvention and with other roof components.

In describing the invention, certain embodiments have been used toillustrate the invention and the practices thereof. However, theinvention is not limited to these specific embodiments as otherembodiments and modifications within the spirit of the invention willreadily occur to those skilled in the art on reading this specification.Thus, the invention is not intended to be limited to the specificembodiments disclosed, but is to be limited only by the claims appendedhereto.

1. Roof component assemblies for use in a self-adhered roof system,comprising: a base sheet assembly; the base sheet assembly consistingessentially of a waterproof self-adhering base sheet for forming awatertight roof system layer and adhering to an overlying and anunderlying roof system layer, a bottom surface release sheet forming abottom surface of the base sheet assembly, and a top surface releasesheet forming a top surface of the base sheet assembly; the waterproofself-adhering base sheet having a length, a width and a thickness; thewaterproof self-adhering base sheet having a bottom major surface and atop major surface defined by the length and the width of the waterproofself-adhering base sheet; the waterproof self-adhering base sheetconsisting essentially of a reinforcing layer encapsulated within aself-adhering bitumen that forms the bottom major surface and the topmajor surface of the waterproof self-adhering base sheet; the bottomsurface release sheet overlying and being substantially coextensive withthe bottom major surface of the waterproof self-adhering base sheet toprotect the bottom major surface of the waterproof self-adhering basesheet from damage during storage, shipment and handling and beingremovable from the bottom major surface of the waterproof self-adheringbase sheet immediately prior to installation of the waterproofself-adhering base sheet on an underlying layer of a roof system; withthe bottom surface release sheet removed from the bottom major surfaceof the waterproof self-adhering base sheet, the bottom major surface ofthe waterproof self-adhering base sheet being self-adhering for forminga watertight bond with an underlying roof system layer primarily by theapplication of pressure; the top surface release sheet overlying andbeing substantially coextensive with the top major surface of thewaterproof self-adhering base sheet to protect the top major surface ofthe waterproof self-adhering base sheet from damage during storage,shipment and handling and being removable from the top major surface ofthe waterproof self-adhering base sheet immediately prior to anapplication of an overlying roof layer to the top major surface of thewaterproof self-adhering base sheet; with the top surface release sheetremoved from the top major surface of the waterproof self-adhering basesheet, the top major surface the waterproof self-adhering base sheetbeing self-adhering for forming a watertight bond with an overlying roofsystem layer primarily by the application of pressure.
 2. The roofcomponent assemblies for use in a self-adhered roof system according toclaim 1, including: a cap sheet assembly; the cap sheet assemblyconsisting essentially of a waterproof fire-retardant cap sheet forforming a watertight topmost layer of a roof system adhered to anunderlying roof system layer formed by a plurality of the waterproofself-adhering base sheets, a bottom surface release sheet forming abottom surface of the cap sheet assembly, and a top surface selvage edgeportion release sheet forming one lateral edge portion of a top surfaceof the cap sheet assembly; the waterproof fire-retardant cap sheethaving a length, a width and a thickness; the waterproof fire-retardantcap sheet having a bottom major surface and a top major surface definedby the length and the width of the waterproof fire-retardant cap sheet;the waterproof fire-retardant cap sheet consisting essentially of areinforcing layer encapsulated within a fire-retardant modified bitumen,which forms the bottom major surface and a selvage edge portion of thetop major surface of the waterproof fire-retardant cap sheet, and a topmajor surface coating layer forming a remainder of the top major surfaceof the waterproof fire-retardant cap sheet; the bottom surface releasesheet overlying and being substantially coextensive with the bottommajor surface of the waterproof fire-retardant cap sheet to protect thebottom major surface of the waterproof fire-retardant cap sheet fromdamage during storage, shipment and handling and being removable fromthe bottom major surface of the waterproof fire-retardant cap sheetimmediately prior to installation of the waterproof fire-retardant capsheet on an underlying roof system layer formed by a plurality of thewaterproof self-adhering base sheets to form a watertight bond with theunderlying roof system layer primarily by the application of pressure;the top selvage edge portion release sheet overlying and beingsubstantially coextensive with the selvage edge portion of the top majorsurface of the waterproof fire-retardant cap sheet to protect theselvage edge portion of the top major surface of the waterprooffire-retardant cap sheet from damage during storage, shipment andhandling and being removable from the selvage edge portion of the topmajor surface of the waterproof fire-retardant cap sheet immediatelyprior to an application and bonding of an overlapping portion of anadjacent cap sheet to the selvage edge portion of the top major surfaceof the waterproof fire-retardant cap sheet to form a watertight bondwith the overlapping portion of the adjacent cap sheet.
 3. A method ofmaking a self-adhered roof system, comprising: providing a plurality ofbase sheet assemblies; each of the base sheet assemblies consistingessentially of a waterproof self-adhering base sheet for forming awatertight roof system layer and adhering to an underlying and anoverlying roof system layer, a bottom surface release sheet forming abottom surface of the base sheet assembly, and a top surface releasesheet forming a top surface of the base sheet assembly; the waterproofself-adhering base sheet having a length, a width and a thickness; thewaterproof self-adhering base sheet having a bottom major surface and atop major surface defined by the length and the width of the waterproofself-adhering base sheet; the waterproof self-adhering base sheetconsisting essentially of a reinforcing layer encapsulated within aself-adhering bitumen that forms the bottom major surface and the topmajor surface of the waterproof self-adhering base sheet; the bottomsurface release sheet overlying and being substantially coextensive withthe bottom major surface of the waterproof self-adhering base sheet toprotect the bottom major surface of the waterproof self-adhering basesheet from damage during storage, shipment and handling and beingremovable from the bottom major surface of the waterproof self-adheringbase sheet immediately prior to installation of the waterproofself-adhering base sheet on an underlying roof system layer; with thebottom surface release sheet removed from the bottom major surface ofthe waterproof self-adhering base sheet, the bottom major surface of thewaterproof self-adhering base sheet being self-adhering for forming awatertight bond with an underlying roof system layer primarily by theapplication of pressure; the top surface release sheet overlying andbeing substantially coextensive with the top major surface of thewaterproof self-adhering base sheet to protect the top major surface ofthe waterproof self-adhering base sheet from damage during storage,shipment and handling and being removable from the top major surface ofthe waterproof self-adhering base sheet immediately prior to anapplication of an overlying roof system layer to the top major surfaceof the waterproof self-adhering base sheet; with the top surface releasesheet removed from the top major surface of the waterproof self-adheringbase sheet, the top major surface the waterproof self-adhering basesheet being self-adhering for forming a watertight bond with anoverlying roof system layer primarily by the application of pressure;and forming a watertight roof system layer with a plurality of thewaterproof self-adhering base sheets by removing the bottom surfacerelease sheets from the plurality waterproof self-adhering base sheetsand pressing the waterproof self-adhering base sheets against anunderlying roof system layer.
 4. The method of making a self-adheredroof system according to claim 3, including: forming a watertight bondbetween an overlying roof system layer and the watertight roof systemlayer formed of the plurality of waterproof self-adhering base sheets byremoving the top surface release sheets from the plurality of waterproofself-adhering base sheets and pressing roofing components of theoverlying roof system layer against the top major surfaces of theplurality of waterproof self-adhering base sheets.
 5. The method ofmaking a self-adhered roof system according to claim 4, wherein: theroofing components of the overlying roof system layer are a plurality ofwaterproof fire-retardant cap sheets.
 6. The method of making aself-adhered roof system according to claim 5, wherein: the plurality ofwaterproof fire-retardant cap sheets are provided from a plurality ofcap sheet assemblies; each of the cap sheet assemblies consistingessentially of one waterproof fire-retardant cap sheet for forming awatertight topmost roof system layer when adhered to an underlying roofsystem layer formed by the waterproof self-adhering base sheets, abottom surface release sheet forming a bottom surface of the cap sheetassembly, and a top surface selvage edge portion release sheet formingone lateral edge portion of a top surface of the cap sheet assembly; thewaterproof fire-retardant cap sheet having a length, a width and athickness; the waterproof fire-retardant cap sheet having a bottom majorsurface and a top major surface defined by the length and the width ofthe waterproof fire-retardant cap sheet; the waterproof fire-retardantcap sheet consisting essentially of a reinforcing layer encapsulatedwithin a fire-retardant modified bitumen, which forms the bottom majorsurface and a selvage edge portion of the top major surface of thewaterproof fire-retardant cap sheet, and a top major surface coatinglayer forming a remainder of the top major surface of the waterprooffire-retardant cap sheet; the bottom surface release sheet overlying andbeing substantially coextensive with the bottom major surface of thewaterproof fire-retardant cap sheet to protect the bottom major surfaceof the waterproof fire-retardant cap sheet from damage during storage,shipment and handling and being removable from the bottom major surfaceof the waterproof fire-retardant cap sheet immediately prior toinstallation of the waterproof fire-retardant cap sheet on an underlyingroof system layer formed by the waterproof self-adhering base sheets toform a watertight bond with the underlying roof system layer ofwaterproof self-adhering base sheets primarily by the application ofpressure; the top selvage edge portion release sheet overlying and beingsubstantially coextensive with the selvage edge portion of the top majorsurface of the waterproof fire-retardant cap sheet to protect theselvage edge portion of the top major surface of the waterprooffire-retardant cap sheet from damage during storage, shipment andhandling and being removable from the selvage edge portion of the topmajor surface of the waterproof fire-retardant cap sheet immediatelyprior to an application and bonding of an overlapping portion of anadjacent cap sheet to the selvage edge portion of the top major surfaceof the waterproof fire-retardant cap sheet to form a watertight bondwith the overlapping portion of the adjacent cap sheet.
 7. The method ofmaking a self-adhered roof system according to claim 3, wherein: theunderlying roof system layer is formed of a plurality of the waterproofself-adhering base sheets; and the self-adhering bitumen bottom majorsurfaces of the watertight roof system layer are bonded directly to theself-adhering bitumen top major surfaces of the waterproof self-adheringbase sheets of the underlying roof system layer.
 8. The method of makinga self-adhered roof system according to claim 4, wherein: the overlyingroof system layer is formed of a plurality of the waterproofself-adhering base sheets; and the self-adhering bitumen top majorsurfaces of the watertight roof system layer are bonded directly to theself-adhering bitumen bottom major surfaces of the waterproofself-adhering base sheets of the overlying roof system layer.
 9. Aself-adhered roof system, comprising: a watertight roof system layerformed of a plurality of waterproof self-adhering base sheets; each ofthe waterproof self-adhering base sheets having a length, a width and athickness; each of the waterproof self-adhering base sheets having abottom major surface and a top major surface defined by the length andthe width of the waterproof self-adhering base sheet; each of thewaterproof self-adhering base sheets consisting essentially of areinforcing layer encapsulated within a self-adhering bitumen that formsthe bottom major surface and the top major surface of the waterproofself-adhering base sheet; and an underlying roof system layer bondeddirectly to the self-adhering bitumen bottom major surfaces of thewaterproof self-adhering base sheets of the watertight roof system layerby a bond formed primarily by the application of pressure.
 10. Theself-adhered roof system according to claim 9, wherein: the underlyingroof system layer is formed of a plurality of the waterproofself-adhering base sheets; and the self-adhering bitumen bottom majorsurfaces of the watertight roof system layer are bonded directly to theself-adhering bitumen top major surfaces of the waterproof self-adheringbase sheets of the underlying roof system layer.
 11. The self-adheredroof system according to claim 9, including: an overlying roof systemlayer that is bonded directly to the self-adhering bitumen top majorsurfaces of the waterproof self-adhering base sheets of the watertightroof system layer by a bond formed primarily by the application ofpressure.
 12. The self-adhered roof system according to claim 11,wherein: the overlying roof system layer is formed of a plurality of thewaterproof self-adhering base sheets; and the self-adhering bitumen topmajor surfaces of the watertight roof system layer are bonded directlyto the self-adhering bitumen bottom major surfaces of the waterproofself-adhering base sheets of the overlying roof system layer.
 13. Theself-adhered roof system according to claim 11, wherein: the roofingcomponents of the overlying roof system layer are a plurality ofwaterproof fire-retardant cap sheets.
 14. The self-adhered roof systemaccording to claim 13, wherein: each of the waterproof fire-retardantcap sheets has a length, a width and a thickness; each of the waterprooffire-retardant cap sheet having a bottom major surface and a top majorsurface defined by the length and the width of the waterprooffire-retardant cap sheet; each of the waterproof fire-retardant capsheet consisting essentially of a reinforcing layer encapsulated withina fire-retardant modified bitumen, which forms the bottom major surfaceand a selvage edge portion of the top major surface of the waterprooffire-retardant cap sheet, and a top major surface coating layer forminga remainder of the top major surface of the waterproof fire-retardantcap sheet.